U.S. patent number 3,650,232 [Application Number 05/070,034] was granted by the patent office on 1972-03-21 for method and apparatus for manufacturing lead frames.
This patent grant is currently assigned to AMP Incorporated. Invention is credited to Frederick Jay Heinlen.
United States Patent |
3,650,232 |
Heinlen |
March 21, 1972 |
METHOD AND APPARATUS FOR MANUFACTURING LEAD FRAMES
Abstract
Lead frames having plate-like heat sink portion and three leads,
one of which is integral with heat sink, are manufactured by
blanking heat sink and leads, bending the integral lead relative to
the heat sink, forming ends of the remaining leads, and again
bending integral leads so that leads are in a plane which is
parallel to, and spaced from, the heat sink.
Inventors: |
Heinlen; Frederick Jay (Etters,
PA) |
Assignee: |
AMP Incorporated (Harrisburg,
PA)
|
Family
ID: |
22092718 |
Appl.
No.: |
05/070,034 |
Filed: |
September 8, 1970 |
Current U.S.
Class: |
29/827; 29/830;
257/E23.044; 174/548; 174/536; 174/555 |
Current CPC
Class: |
H01L
21/4842 (20130101); H01L 21/67144 (20130101); H01L
23/49562 (20130101); H01L 2924/00 (20130101); H01L
2924/0002 (20130101); Y10T 29/49121 (20150115); Y10T
29/49126 (20150115); H01L 2924/0002 (20130101) |
Current International
Class: |
H01L
21/48 (20060101); H01L 21/00 (20060101); H01L
23/495 (20060101); H01L 23/48 (20060101); H01L
21/02 (20060101); B01j 017/00 (); H01l
001/10 () |
Field of
Search: |
;113/119,1R ;174/DIG.3
;317/234N ;29/630,576S,193.5 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Herbst; Richard J.
Claims
I claim:
1. A method of manufacturing lead frames in the form of a
continuous strip comprising the steps of:
blanking strip metal stock to form a succession of side-by-side
lead frame blanks, each of said blanks comprising a mounting plate
portion and three leads extending transversely with respect to the
axis of said strip, the center one of said leads being connected to
one edge of said mounting plate portion by a connecting strap
portion, the outside ones of said leads each having a contact arm
on its inner end, said arms extending in opposite directions along
the length of said strip, said leads being connected to each other
by integral tie bar means,
bending said arms laterally of the plane of said strip,
bending said connecting strap at a location remote from said one
edge to swing said leads in one direction along an arcuate path and
to orient said leads in a plane extending transversely of the plane
of said strip with said arms disposed on one side of said mounting
plate portion and with the free ends of said leads disposed on the
side opposite to said one side,
further forming said arms substantially to their final
configuration, and
bending said connecting strap at a location proximate to said one
edge of said mounting plate portion to swing said leads along an
arcuate path in a direction opposite to said one direction and
orient said leads in a plane which is parallel to, and spaced from,
the plane of said strip with said arms between said planes.
2. The method set forth in claim 1 wherein said arms are initially
bent partially towards each other.
3. The method set forth in claim 1 wherein said arms are initially
bent partially towards each other and during further forming, said
arms are bet inwardly until their ends are spaced apart by a
distance which is less than the width of said connecting strap
portion.
4. The method set forth in claim 3 including the step of further
forming said connecting strap portion by bending said strap portion
at both said locations until said strap portion extends reversely
between said plane and the plane of said strip.
5. A method of manufacturing lead frames in the form of a
continuous strip comprising the steps of:
blanking strip metal stock to form a succession of side-by-side
lead frame blanks, each of said blanks comprising a mounting plate
portion and three leads beside said mounting plate portion, said
leads extending transversely of the axis of said strip, the center
one of said leads being connected to one edge of said mounting
plate portion by a connecting strap portion, the outside ones of
said leads having inner ends spaced from said edge and each having
a contact arm extending therefrom, said arms extending parallel to
the axis of said strip in opposite directions, said leads being
connected to each other by integral tie bar means,
bending said arms laterally Of the plane of said strip and
partially inwardly towards each other,
bending said connecting strap at a first location remote from said
one edge to swing said leads about said location in one direction
so that said leads are in a plane extending normally of the plane
of said strip with said arms disposed on one side of said mounting
plate portion and with the free ends of said leads on the side
opposite to said one side,
further forming said arms towards each other until the ends of said
arms spaced apart by a distance which is less than the width of
said strap,
bending said connecting strap at a second location proximate to
said one edge of said mounting plate portion to swing said leads
about said second location in a direction opposite to said one
direction thereby to orient said leads in a second plane which is
parallel to, and spaced from, the plane of said strip, and
further bending said connecting strap portion at said first and
second locations to move portions of said leads past said one edge
and position said arms at a predetermined location with respect to
said mounting plate portion.
6. A method of manufacturing lead frames in the form of a
continuous strip, each lead frame being of the type comprising a
mounting plate disposed in a first plane and three parallel leads
disposed in a second plane which is parallel to, and spaced from,
said first plane, said leads being joined to each other by an
integral tie bar extending transversely of the axes of said leads,
the center one of said leads being joined to one edge of said
mounting plate by a connecting strap, which extends between said
planes, outside ones of said leads extending over said mounting
plate and past said one edge and having contact arms on their ends
extending laterally in opposite directions, said arms being
reversely bent towards said mounting plate and towards each other,
the ends of said arms being spaced-apart by a predetermined
distance which is less than the width of said connecting strap and
being disposed between said planes, said method comprising the
steps of:
blanking strip stock metal to define said mounting plate, said
leads, said tie bar, and said connecting strap in said first plane
with said leads extending transversely of the length of said strip
and with said contact arms extending laterally in opposite
directions from said outside leads,
bending said contact arms laterally of said first plane and away
from said first and second planes and further bending said arms
partially inwardly and towards each other so that the distance
between the ends of said arms is greater then the width of said
connecting strap,
forming a first right angle bend in said strap at a first location
adjacent to said center lead whereby said leads are swung along an
arcuate path and are directed away from said first and second
planes, and said arms are swung along an arcuate path past said
strap and are disposed on the opposite side of said first plane
from said free ends of said leads,
further forming said arms inwardly and towards each other until
they are spaced apart by said predetermined distance,
forming a second angle bend in said strap at a second location
adjacent to said one edge of said mounting plate towards said
second plane until said strap extends between said second and first
planes whereby said leads and said tie bars are moved along an
arcuate path into said second plane and said arms are disposed
between said planes and spaced from said mounting plate, and
bending said strap at said first and second locations until said
strap extend reversely with reference to said planes and said leads
extend in said second plane beyond said one edge.
7. Stamping and forming apparatus for the production of a lead
frame of the type comprising a mounting plate disposed in a first
plane and three parallel leads disposed in a second plane which is
parallel to, and spaced from, said first plane, said leads being
joined to each other by an integral tie bar extending transversely
of the axes of said leads, the center one of said leads being
joined to one edge of said mounting plate by a connecting strap
which extends between said planes, the outside ones of said leads
extending over said mounting plate and past said one edge and
having contact arms on their ends extending laterally in opposite
directions, said arms being reversely bent towards said mounting
plate and towards each other, the ends of said arms being
spaced-apart by a predetermined distance which is less than the
width of said connecting strap and being disposed between said
planes, said apparatus comprising:
blanking means for blanking strip metal stock to form said mounting
plate, said leads, said tie bar and said arms with said leads
extending transversely of the length of said strip and with said
contact arms extending in opposite directions along the length of
said strip,
first arm forming means for bending said arms laterally of the
plane of said stock in a first direction and partially inwardly
towards each other while leaving a spacing between the tips of said
arms which is greater than the width of said connecting strap so
that said tips are on each side of, and beyond the sides of said
connecting strap,
first strap bending means for bending said connecting strap at a
location adjacent to the end of said center lead in said first
direction whereby said leads and said tie bar are swung along an
arcuate path until said leads extend in said first direction, and
said arms are concomitantly swung along an arcuate path past said
connecting strap so that the ends of said outside leads extend in a
second direction which is opposite to said first direction
second arm forming means for bending said arms further inwardly
towards each other until said tips of said arms are spaced apart by
a distance which is less than the width of said strap, and
second strap bending means for bending said strap at a location
adjacent to said plate in said second direction whereby all of said
leads are swung along an arcuate path into said second plane and
said connecting strap extends between said planes.
Description
BACKGROUND OF THE INVENTION
A known type of transistor lead frame shown in the Patent to
Tascovich U.S. Pat. No. 3,597,666, comprises a relatively massive
heat sink, on which the transistor or chip is mounted, and three
leads which are disposed in a plane extending parallel to, and
spaced from, the heat sink. The center lead is connected to the
heat sink and the ends leads have their end portions extending over
the surface of the heat sink and are reversely bent towards each
other so that their tips lie between the two planes. The transistor
is disposed beneath the tip portions of the outside leads and these
tips are bonded to the contact portions of the chip, the center
lead serving as a collector for the transistor.
Lead frames of the type described above required leads of
relatively thin stock metal. They also require a relatively thick
heat sink to provide the required heat dissipation ability. Because
of this fact, and because of the relative complexity of this type
of lead frame, it has been customary in the past to manufacture
such lead frames from two separate strips which are subsequently
assembled to each other. The heat sinks are manufactured by
stamping a relatively thick metal strip and the leads are
manufactured by stamping and forming a relatively thin strip. The
collector lead, in accordance with prior art practice, may then be
assembled to the heat sink by a clinching or other mechanical
fastening operation.
The instant invention is directed to the achievement of a one piece
transistor lead frame having a relatively thick platelike heat sink
section and three leads which are intricately formed in spaced
relationship to the heat sink. It is accordingly an object of the
invention to provide an improved method and apparatus for
manufacturing transistor lead frames. It is a further object to
provide a method and apparatus for manufacturing lead frames having
a heat sink and having intricately formed leads in the form of a
continuous strip. It is a further object to provide an improved
stamping and forming die for the manufacture of lead frames. It is
a further object to provide a method and apparatus for carrying out
stamping, bending, and forming operations on a metal strip to
produce a lead frame having two metal thicknesses and having
intricately formed lead ends. A still further object is the
achievement of a lead frame having pre-applied solder on its heat
sink portion and on the ends of its contact arms.
These and other objects of the invention are achieved in a
preferred embodiment thereof which is briefly described in the
foregoing abstract, which is described in detail below, and which
is illustrated in the accompanying drawings in which:
FIG. 1 is a perspective view of a stamping and forming die in
accordance with the invention for producing lead frames in strip
form in accordance with the method of the invention.
FIG. 2 is a plane view of the forming die of FIG. 1 with portions
of the upper die shoe broken away to reveal portions of the tooling
in the lower die shoe.
FIGS. 3A and 3B are plan views of a strip progression produced by
the progressive die of FIG. 1, this view illustrating the
successive stages in the formation of lead frames in accordance
with the invention; FIGS. 3A and 3B are adapted to be placed beside
each other to show the complete progression.
FIG. 3C is a perspective view of a short section of lead frame
strip in accordance with the invention.
FIG. 3D is a perspective view of a short section of heat metal
stock of the type used to produce lead frames in accordance with
the invention.
FIG. 4 is a plane view on an enlarged scale of the tooling in the
lower die shoe for initially bending the ends of the outside leads
downwardly.
FIG. 5 is a view taken along the lines 5--5 of FIG. 4.
FIG. 6 is a view taken along the lines 6--6 of FIG. 4 showing the
positions of the lower and upper tooling prior to the initial
bending and forming operations which are performed on the contact
arms.
FIG. 7 is a view similar to FIG. 6 but showing the positions of the
parts when the upper tooling has been moved downwardly into
engagement with the lower tooling and after the bending and forming
operations have been carried out.
FIG. 8 is a sectional view taken along the lines 8--8 of FIG. 2
illustrating the tooling at the first bending station of the die in
which all of the leads are bent downwardly from their original
planes.
FIG. 9 is a view similar to FIG. 8 but showing the positions of the
parts after the initial lead bending operation has been carried
out.
FIG. 10 is a view taken along the lines 10--10 of FIG. 2 showing
the upper and lower tooling for further forming the contact arms on
the ends of the outside leads.
FIG. 11 is a view similar to FIG. 10 but showing the positions of
the parts at the conclusion of this arm forming operation.
FIG. 12 is a view taken along the lines 12--12 of FIG. 10.
FIG. 13 is a view taken along the lines 13--13 of FIG. 11.
FIG. 14 is a view taken along the lines 14--14 of FIG. 2 showing
the station at which the leads are bent back into a plane parallel
to the plane of the heat sink.
FIG. 15 is a view similar to FIG. 14 but showing the positions of
the parts at the conclusion of this second bending operation.
FIG. 16 is a view taken along the lines 16--16 of FIG. 15.
FIG. 16A is a fragmentary perspective view of an upper bending tool
shown in FIG. 16.
FIG. 17 is a view taken along the lines 17--17 of FIG. 2 and
showing a forming station at which the connecting strap, which
extends between the collector lead and the heat sink is bent to
position the outside leads centrally above the heat sink.
FIG. 18 is a view similar to FIG. 17 but showing the positions of
the parts at the conclusion of this connecting strip forming
operation.
FIG. 19 is a view taken along the lines 19--19 of FIG. 2
illustrating the tooling which is provided at a final sizing and
forming station.
FIG. 20 is a view similar to FIG. 19 but showing the positions of
the parts after the final sizing and forming operation has been
carried out.
FIG. 21 is a view taken along the lines 21--21 of FIG. 20.
Referring first to FIG. 3C, a typical transistor lead frame 2 of
the type adapted to be produced in accordance with the method of,
and by a stamping and forming die in accordance with, the instant
invention comprises a relatively thick and massive metallic heat
sink 4 having three leads 6, 8, 10 associated therewith. These
leads are disposed in a plane which extends parallel to, and is
spaced from, the plane of the heat sink 4, the center lead 8 being
reversely bent at its inner end 13 and including a reversely
extending connecting strap portion 12 which is integral with one
edge 14 of heat sink 4 as indicated at 15. The outside leads 6, 10
have end portions 18 which extend over the upper surface of the
heat sink 4 and past the edge 14. These outside leads have contact
arms 20 on their ends which extend laterally in opposite directions
and which are reversely bent downwardly towards the heat sink and
inwardly towards each other so that the tips 24 of these arms are
disposed in front of the connecting strap 12 and immediately above
the surface of the heat sink. It should be noted at this point that
these arm tips 24 are spaced apart by a distance which is
substantially less than the width of the connecting strip 12 of
center lead 8. This spacing is relatively critical for the reason
that the tips of these contact arms will be bonded, to the contact
areas of the chip which is mounted on the heat sink. The outer arms
6, 10 are not directly connected to the heat sink 4 but are
integral with the center lead 8 by virtue of the presence of a
transversely extending tie bar 16.
When a transistor is assembled to the frame 2, the transistor or
chip is placed on the upper surface of heat sink 4 with the tip
portions 24 of the contact arms disposed against the contact areas
of the chip. The chip has a thickness which is somewhat greater
than the spacing between the ends 24 of the arms and the surface of
the heat sink so that the chip is resiliently held in position
while the frame is passed through a furnace in which solder metal
26 on the surface of the heat sink is reflowed to secure the chip
to the frame. Thereafter, the ends of the leads, the chip, and
portions of the heat sink are encapsulated by a molding process,
the tie bar 16 functioning as a mold closure or dam bar during
molding. The portions of the tie bar which extend between the leads
are then removed by a stamping operation so that they are
electrically separated from each other.
Turning now to FIGS. 3A, 3B, and 3D the method aspect of the
invention is illustrated by the progression which shows the
successive stamping and forming steps performed on strip metal to
produce the finished lead frame. The strip metal stock 30, FIG. 3D,
has a relatively thick section 32 and a relatively thin section 34
with a preapplied solder stripe on the surface of the thick section
and adjacent portions of the thin section. Stock metal of this type
may be produced by rolling or milling metal strip having a uniform
thickness. Frames in accordance with the invention are
conventionally produced from copper alloy stock which has been
plated with nickel although other metals may be used.
As the stock metal passes through the die 48, which is described
below, pilot holes 36, 38 are first punched and a generally
rectangular opening 39 is formed in the thin stock section 34 in
overlapping relationship to the edge of the solder stripe 26.
Thereafter, an elongated opening 40 is punched beside each of the
openings or holes 39, this opening 40 having a laterally extending
recess intermediate its ends. The leads are initially formed by
punching the upper edge, as viewed in the drawing, of the thin
stock section and relatively thin slits 42 are then punched on each
side of each opening 39 as shown at the location indicated at 41.
The operation of punching these narrow openings or slits 42 defines
the connecting strip portion 12' of the incipient lead frames and
the contact arms 20' of two adjacent frames are formed when a short
section of the stock between two adjacent frames is removed. The
leads 6, 8, 10 are then stamped so that they have a generally
U-shaped cross section as shown at 62. Subsequently at 43, FIG. 3A,
the contact arms 20' are bent downwardly and, as will be explained
below, partially inwardly towards each other. However, the spacing
between the tips of the arms at this stage is greater than the
width of the connecting strap portions 12' of the incipient
frames.
Subsequently, some conventional punching and coining operations are
carried out to remove stock metal between adjacent lead frames and
to coin and finally form the sides of the heat sinks.
At location 44, the connecting strap section 12 of the center lead
is bent at a location 13 which is remote from the heat sink so that
all of the leads now extend normally of the plane of the stock
metal. During such bending, the partially formed ends of the
outside leads 6, 10 are swung along an arcuate path past the edges
of the connecting section 12 of the center lead so that the contact
arms are now above the surface of the connecting strap 12 of the
center lead. These contact arms can now be formed inwardly until
they are spaced apart by the required precisely predetermined
distance which is less than the width of the connecting strap.
At location 46, the connecting strap section 12 is bent at 15
adjacent to edge 4 of the heat sink so that the leads are swung
along an arcuate path until they are disposed above the plane of
the heat sink and the connecting strap is then further formed or
bent until it extends reversely between the planes defined by the
heat sink and the leads. A final sizing and forming operation may
be carried out to precisely locate the leads relative to the heat
sink.
Turning now to FIGS. 1 and 2, a preferred form of stamping and
forming die 48 in accordance with the invention comprises an upper
die shoe 50, a lower die shoe 52 and guides 54 which guide the
upper shoe towards the lower shoe. A die set of the type shown at
48 is adapted to be placed in a conventional punch press in
accordance with conventional stamping and forming techniques and
contains lower and upper tooling 58, 60 which progressively forms
strip metal stock as it moves therethrough. The lower tooling 56 is
mounted in a channel-shaped depression 58 extending the length of
the die and in other recesses more fully described below and the
upper tooling 60 is similarly mounted in the upper die shoe.
As shown in FIG. 2, the lower die tooling is mounted in separate
blocks in the lower die but a generally channel-shaped depression
62 is provided which extends for the full length of the die and
through which the heat sink portions 4 of the strip are fed. The
leads 6, 8, 10 extend downwardly as viewed in FIG. 2 towards the
front portion 74 of the lower die shoe so that they are carried
past the forming stations.
The initial punching operations in which the openings 36, 38, 39,
40 and 42 are formed are now shown inasmuch as conventional
punching practice can be employed for these operations.
After the punching operations have been carried out, the ends of
the leads 6, 8, 10 are U'd or dished by dies 64 mounted in a recess
66 and in cooperation with suitable punches. Thereafter, the ends
of the contact arms 20' on the ends of the outside leads 6, 8 are
formed downwardly as shown in FIGS. 4-7. The lower tooling for this
initial arm forming operation is mounted on a slide 70 which is
disposed in a groove 72 extending from the strip feed path across
the front section 74 of the lower die shoe, suitable guides 76
being provided on each side of this slide to guide it accurately
towards and away from the strip which is being fed through the die.
Slide 70 has a slot or recess 80 in its end adjacent to the front
side of the die shoe and a pin 82 is mounted in the slide and
extends through this recess. The slide is reciprocated towards and
away from the strip by a very slight distance by a camming rod 84
(FIG. 5) which extends from the upper die shoe into recess 80 and
which has contoured surfaces as indicated that are effective to
drive the slide inwardly during downward movement of the upper die
shoe and to retract it during upward movement thereof.
Referring now to FIG. 6, the arms 20' of each blank, as it passed
this initial forming station, are moved above a mandrel block 88
which is mounted on one side of the forward end of the slide 70, a
recess 86 being provided beneath this mandrel to permit the bending
operation described below. After feeding of the strip, the
connecting strap portion 12' of the center lead will be supported
on the upper surface of block 88 and the end portions of the arms
20' will extend laterally beyond the sides of this block. A
clamping block 90 is mounted in the upper die shoe and is
resiliently biased downwardly by a spring 92 so that as the upper
tooling moves downwardly, the center strap portion 12 and the ends
18 of the leads 6, 10 will be firmly clamped as illustrated in FIG.
7. The laterally projecting contact arm portions 20' are then bent
downwardly against the sides of block 88 by a bending tool 92 which
surrounds the clamping block 90. At the conclusion of this bending
operation then, the arm portions 20 will be bent downwardly as
shown at 22' and will be disposed against the sides of the mandrel
block 88.
Upon subsequent upward movement of the upper tooling 92 the mandrel
block 88 will be retracted from beneath the partially formed leads
so that the strip can be fed leftwardly as viewed in FIGS. 6 and 7
for a further forming operation. At this next forming station,
which appears on the left in FIGS. 4, 6 and 7, the arms are bent
inwardly over a mandrel 96 having curved sides 98. This mandrel
block 96 is also mounted on the inner end of the slide 70 and
between a pair of forming arms 100 which are disposed in a recess
104 in the slide and are pivoted on a common pivot pin 102. Arms
100 are normally biased apart by a spring 106 and have inner ends
which straddle the mandrel block 96 so that when the slide is in
its forward or inner position, these arms will be located on each
side of the depending contact arms of the leads 6, 10. The opposed
surfaces of the forming arms 100 are curved as shown at 108 so that
when the arms are moved towards each other and against the sides 98
of the mandrel 96, the contact arms 22 will be inwardly formed as
shown on the left in FIG. 7. It should be noted that after this
inward bending of the contact arms, they remain spaced apart by a
distance which is greater than the width of the connecting strap
portion 12 of the center lead.
The forming arms 100 are actuated by a camming punch 114 which is
mounted in the upper tooling and which has inclined surfaces 112
that engage the surface 110 of the arms as is apparent from FIGS. 6
and 7 to close the arms 100 against the force of the biasing spring
106. A hold down block or clamping block 116 is mounted in a
central passageway in the camming tooling 114 and is resiliently
biased downwardly by a spring 118 as indicated to clamp the
connecting strap 12 and the ends of the contact leads 18 as is also
apparent from FIG. 7.
After the second arm forming operation of FIGS. 6 and 7, the slide
70 is retracted and the mandrel 96 moves from beneath the
previously formed contact arms so that the strip can then be fed to
subsequent forming stations. Since the contact arms now extend
downwardly and beneath the plane of the strip stock, it is
necessary to provide a recess or groove 124 for these depending
contact arms as indicated in FIG. 8.
Referring again to FIG. 2, further punching operations are carried
out at 120 to remove the remaining finger like portion 121 of stock
metal between adjacent incipient lead frames. Additionally, the
coining operation for forming the sides of the heat sinks may be
carried out as shown at 122. Since these are conventional die
forming operations, the tooling is not shown in detail although the
coining and punching dies are apparent in FIG. 2.
Referring now to FIGS. 8 and 9, the connecting strap section of the
central lead 8 is bent at 13 to swing the free ends of all of the
leads 6, 8, 10 along an arcuate path downwardly while the inner end
portions 18 of the outside leads and the contact arms 20 extending
therefrom are swung along an arcuate path upwardly relative to the
lower die shoe. This bending operation is carried out by means of a
bending tool 132 mounted in the upper die shoe, a recess 126 in one
of the die blocks 128 being provided to permit the downward
movement of the leads. A forming plate 130 is mounted on the
right-hand side of this recess as viewed in FIG. 8 so that its
upper surface 130 supports the connecting strap portion of the
central lead. The bending tool 132 has a relatively narrow
projection 134 on its forwardly facing side which is above the
lower surface 133 of this tool. As the bending tool is lowered, the
leads are swung downwardly along an arcuate path until the
underside of projection 134 moves against the surface of the
connecting strap portion of the central lead as shown at FIG. 9.
The leads will then extend in a vertical plane and the contact arms
will be disposed above the plane of the heat sink as is apparent
from FIG. 9.
As shown in FIGS. 10-13, the ends of the contact arms are then bent
inwardly and given their final configuration by tooling comprising
a slide member 138 and a punch 140 which forms part of the upper
tooling. Punch 140 has a channellike recess 142 in its forwardly
facing side (FIG. 13), the width of which is substantially equal to
the spacing between the outside surfaces of the contact arms. When
this punch is lowered, during downward movement the upper die shoe,
the slide 138 moves leftwardly as viewed in FIG. 10 and towards the
punch. This slide has a recess 144 on its forward end and contoured
surfaces 146 which move against the outside surfaces of the contact
arms and bend these arms inwardly until their ends 24 are spaced
apart by the previously mentioned predetermined distance which is
less than the width of the connecting strap 12. Slide 138 has a
plate 148 on its upper surface to form the contact arms downwardly
and to confine then during the final forming and bending operation.
The slide is actuated by a slide block 150 which in turn is mounted
in a recess in the lower die shoe and reciprocated by a camming rod
152. This camming rod is mounted in the upper die shoe as
previously described with reference to FIG. 5.
Subsequent to the inward forming of the contact arms as illustrated
in FIGS. 10-13, the connecting strap is again bent through a 90
.degree.angle at a location 15 adjacent t0 the edge 4 of the heat
sink so that the leads are then swung through a 90 .degree.angle
along an arcuate path and are disposed in a plane which is parallel
to, but above, the plane of the heat sink. After this second
bending step, the surface portions of the ends 24 of the contact
arms, which have pre-applied solder thereon, will be facing the
surface of the heat sink to permit soldering to the chip. The
tooling for performing this second bending operation on the
connecting strap, FIGS. 14-16 comprises an upper bending tool 157
and a lower bending tool 162 which is integral with a block mounted
in a slot 161 in the lower die shoe. A recess in the lower tooling
165 is provided on the left-hand side, as viewed in FIG. 14, of
block 160 to provide clearance for the leads as they are swung
along an arcuate path as will be apparent from a comparison of
FIGS. 14 and 15. In its normal position, the slide 160 is beneath
the lower surface of the heat sink and the bending tool 162 is
against the underside of the connecting strap portion of the lead
frame. The upper bending tool has generally parabolic recesses 157a
on its leftwardly facing side (as viewed in FIGS. 15 and 16A) which
are separated by a vertically extending rib or projection 158. This
projection has laterally extending foot portions 158a on its lower
end so that it clamps the connecting strap portion of the lead
frame but permits arcuate movement of the formed arms from the
positions of FIG. 14 to the positions of FIG. 15.
When the upper bending tool 157 moves downwardly and the slide 160
moves upwardly, a shape right angle bend will be imparted at 15 to
the connecting strap portion to bring about the arcuate movement of
the leads and to produce the form indicated at 46 in FIG. 3B. The
upper bending tool 158 is spring loaded and bottoms on the lead
frame before upward movement of slide 160 so that the heat sink and
center lead are clamped securedly before commencement of the
bending operation.
The bending tool 62 and the block 160 are reciprocated by a lever
170, FIG. 14. A pin extends through a slot 166 in the lower end of
block 160 and is received in an open ended slot 168 in the lever
170 which is disposed in a recess 172 in the lower die shoe. THe
right-hand end of this lever is pivoted at 174 to a rod 176 which
extends above the upper surface of the lower die shoe and which is
biased upwardly, as viewed in FIG. 14, by a spring 178 which is
received in a recess in the die shoe and which bears against the
underside of a nut on the upper end of the rod. The shape of the
lever 170 and the dimensions of the recess 172 in which this lever
is mounted are such that when the rod 176 is pushed downwardly by a
depressor rod 180, the block 160 and the forming tooling portion
158 will be moved upwardly from the position of FIG. 14 to the
position of FIG. 15. The rod 180 is mounted in the upper die shoe
and has a length such that upward movement of slide 160 takes place
after the upper forming tool 158 has bottomed and clamped the heat
sink as described above.
Referring now to FIGS. 17 and 18, the connecting strap portion 12
of the center lead is then further formed to increase the bend
angles at 13 and 15 until this strap portion extends obliquely
between the planes defined by the leads and the heat sink thereby
to accurately locate the ends of the contact arms at predetermined
locations above the surface of the heat sink. This bending
operation is carried out by a slide 184 which is supported on a
block 186 across which the strip is fed and which provides a
portion of the channel 62 for the heat sink portion of the strip.
Slide 184 has an undercut end 190 such that when its pointed end
191 moves rightwardly, as viewed in FIGS. 17 and 18, against the
connecting strap portion, a Z-shaped cross sectional configuration
of FIG. 18 will be imparted to the lead frame. In order to control
the positions of the leads an upper tool 182 is provided which has
a recess 188 on its lower end that confines the end portions of the
leads 6 and 8 during this operation and maintains all three leads
in a horizontal attitude.
The slide 184 extends leftwardly in FIG. 17 and is secured to slide
block 192 mounted in a recess in the lower die shoe. Reciprocation
is achieved by means of a camming bar 194 mounted in the upper die
shoe which is similar to the previously described camming bars.
After completion of the forming operation of FIGS. 17 and 18, the
heat sink is substantially in its final form. However, in order to
precisely control the dimensions of the finished part, it is
desirable to carry out a final sizing operation in which an upper
sizing tool 198 moves against the upper surfaces of the leads and
further bends the connecting strap 12 until the leads are against
the upper surface of a gauge block 196. The precise spacing between
the planes of the heat sink and the leads is determined by the
dimensions of a projection 200 which depends from this tool member
and which moves against the upper surfaces of the leads as shown in
FIG. 20.
The operation of this stamping and forming die shown in FIG. 1 will
thus be apparent from the step-by-step descriptions of the
operations as described above and form the description of the
method of the invention presented above with reference to FIGS. 3A
and 3B. A significant feature of the invention is the achievement
of a lead frame of the general type shown in which the ends of the
contact arms are spaced apart by a distance substantially less than
the width of the connecting strap and the length of these arms, as
measured along the curved sections, is greater than the distance
between the two planes of the heat sink and the contact arms. It
will be apparent that this result is achieved by bending the
contact arms partially, then bending the connecting strap, finally
forming the arms, and then finally bending the connecting strap at
its secondary locations.
An additional advantage of the invention is that the end portions
24 of the contact arms which are opposed to the heat sink 4 have
solder thereon. These arms were formed from the solder striped
portion of the metal stock and bent during forming to achieve this
effect.
Changes in construction will occur to those skilled in the art and
various apparently different modifications and embodiments may be
made without departing from the scope of the invention. The matter
set forth in the foregoing description and accompanying drawings is
offered by way of illustration only.
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